Roof laser brazing system

ABSTRACT

A roof laser brazing system comprises a side home position jig installed at each of opposite sides of the transferring path of the body in the brazing section, a roof-pressing jig detachably mounted on a handling robot, docked to the side home position jig, and that home-positions and presses the roof panel loaded on the opposite side panels, a brazing assembly mounted on at least one brazing robot in the side home position jig side and that brazes bonding portions between the opposite side panels and the roof panel using a laser as a heat source, and a grinding assembly mounted on the at least one grinding robot in the grinding section and that grinds brazing beads of the bonding portions between the opposite side panels and the roof panel.

CROSS-REFERENCE TO RELATED APPLICATION

This application is the Divisional application of U.S. patentapplication Ser. No. 14/948,138 filed Nov. 20, 2015, which claims thebenefit of priority to Korean Patent Application No. 10-2015-0108918,filed with the Korean Intellectual Property Office on Jul. 31, 2015, theentire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a vehicle body assembly system. Moreparticularly, the present disclosure relates to a roof laser brazingsystem that assembles side panels and a roof panel of a vehicle body.

BACKGROUND

Generally, a vehicle body is formed as a body in white (BIW) through avehicle body assembly process of assembling various panels produced invehicle body sub-processes.

A vehicle body includes a floor panel forming a lower side of a framethereof, opposite side panels forming left and right sides of the frame,a roof panel forming an upper side of the frame, a plurality of roofrails, a cowl panel, a back panel, a package tray, and other components.Assembling such parts of the vehicle body is performed in a main buckprocess (referred to as a vehicle body build-up process in theindustry).

In the main buck process, after the back panel is bonded to the floorpanel through a vehicle body assembly system, the opposite side panels,the roof panel, the roof rail, the cowl panel and the package tray arewelded and assembled.

The vehicle body assembly system sets the side panels to the floor panelby restricting the side panels by a side hanger and a side gate, andafter it sets the roof panel, the roof rail, the cowl panel, and thepackage tray to the side panel, their bonding portions are welded by awelding robot.

In the vehicle body assembly process, after the roof panel is welded tothe side panels by spot-welding, a roof molding made of resin isattached to the welded portions of the side panels and the roof panel.

However, since the roof molding is attached to the welded portions ofthe side panels and the roof panel in the conventional art, appearancethereof is not good, and material costs and labor costs may increase dueto attachment of the roof molding.

The above information disclosed in this Background section is only toenhance the understanding of the background of the disclosure andtherefore it may contain information that does not form the prior artthat is already known in this country to a person of ordinary skill inthe art.

SUMMARY OF THE DISCLOSURE

The present disclosure has been made in an effort to provide a rooflaser brazing system that can remove a roof molding by laser-brazingportions between a side panel and a roof panel.

An exemplary embodiment of the present disclosure provides a roof laserbrazing system which is configured in a predetermined brazing sectionand a predetermined grinding section along a transferring path of a bodyfor bonding a roof panel to opposite side panels based on the bodyincluding the opposite side panels, including: a side home position jigthat is installed at each of opposite sides of the transferring path ofthe body in the brazing section, and that restricts and home-positionsthe opposite side panels of the body; a roof-pressing jig that isdetachably mounted on a handling robot, is docked to the side homeposition jig, and home-positions and presses the roof panel loaded onthe opposite side panels; a brazing assembly that is mounted on at leastone brazing robot in the side home position jig side and brazes bondingportions between the opposite side panels and the roof panel by using alaser as a heat source; and a grinding assembly that is mounted on theat least one grinding robot in the grinding section and grinds brazingbeads of the bonding portions between the opposite side panels and theroof panel.

The roof laser brazing system may further include a gap measurement unitthat is installed to be movable forward or backward to the brazingassembly and measures matching gaps between the roof panel and theopposite side panels pressed by the roof-pressing jig.

The side home position jig may home-position the opposite side panelsdepending on the matching gaps measured by the gap measurement unit, andmay ensure a zero gap between the opposite side panels and the roofpanel.

The roof laser brazing system may further include a bead inspection unitthat is installed at the grinding assembly, inspects a brazing beadground by the grinding assembly, and senses a position of the body.

The roof laser brazing system may further include: a roof alignment jigthat is installed between the brazing section and the grinding sectionand aligns the roof panel; and a roof loading jig that is detachablyinstalled at the handling robot, unloads the roof panel from the roofalignment jig, and loads the roof panel on the opposite side panels.

Another embodiment of the present disclosure provides a roof laserbrazing system which laser-brazes a roof panel to opposite side panelsbased on a body including the opposite side panels, including: a sidehome position jig that is installed at each of opposite sides of atransferring path of the body in a brazing section set along thetransferring path of the body and restricts the opposite side panels ofthe body; a roof-pressing jig that is detachably mounted on a handlingrobot, is docked to the side home position jig, and home-positions andpresses the roof panel loaded on the opposite side panels; a brazingassembly that is mounted on at least one brazing robot in the side homeposition jig side and brazes bonding portions between the opposite sidepanels and the roof panel by using a laser as a heat source; a gapmeasurement unit that is mounted on the brazing assembly and measuresmatching gaps between the roof panel and the opposite side panels thatare pressed by the roof-pressing jig; and a grinding assembly that ismounted on at least one grinding robot in a grinding section set alongthe transferring path of the body and grinds brazing beads of thebonding portions between the opposite side panels and the roof panel.

The side home position jig may include: a base frame installed at eachof the opposite sides of the transferring path with the transferringpath of the body therebetween; a moving frame installed to bereciprocally and slidably movable in a width direction of the bodythrough a plurality of guide rails provided in the base frame; a postframe disposed in a direction perpendicular to opposite sides of themoving frame; a support frame installed at the post frame along a lengthdirection of the opposite side panels; a plurality of dampers that aremounted on the support frame along the transfer direction of the body,are installed to be reciprocally movable in the width direction of thebody, and restrict the opposite side panels; and a first driving partinstalled at the base frame to reciprocally move the moving frame in thewidth direction of the body.

The first driving part may include: a first servo motor fixedly mountedon the base frame; and a lead screw that is connected to the first servomotor and is substantially screw-fixed to the moving frame.

The clampers may be installed to be reciprocally movable in the widthdirection of the body by a second driving part provided in the supportframe, and the second driving part may include: a second servo motorinstalled at the support frame; and an LM guide that is connected to thesecond servo motor, fixes the damper, and is installed to bereciprocally movable in the width direction of the body by the secondservo motor.

The post frame may include: a fixing pin coupled to fix theroof-pressing jig; a pin clamper installed to restrict a pin connectionportion of the roof-pressing jig; and a support bracket at which thefixing pin and the pin clamper are installed and that is installed todock with the roof-pressing jig.

The roof-pressing jig may include: a jig frame mounted on the handlingrobot; a restriction pad that is installed at each of left and rightsides of the jig frame and supports opposite side edges of the roofpanel along a length direction of the side panel; a plurality of vacuumcups that are installed at the jig frame, respectively pass through aplurality of penetration holes continuously formed in the restrictionpad along the opposite side edges of the roof panel, and vacuum-adsorbskin surfaces the opposite side edges of the roof panel; a restrictionpin that is installed to be vertically movable at the jig frame in afront end side of the restriction pad and is inserted upwardly from alower side with respect to a restriction hole formed in the roof panel;a restriction pin cylinder that is connected to the restriction pin sothat the restriction pin is vertically moved and is installed at the jigframe; a reference pin that is installed to be vertically movable at thejig frame in a rear end side of the restriction pad and is inserteddownwardly from an upper side with respect to a reference hole formed inthe roof panel; and a reference pin cylinder that is connected to thereference pin so that the reference pin is vertically moved and isinstalled at the jig frame.

A docking bracket docked to the side home position jig may be fixedlyinstalled at opposite sides of each of front and rear ends of the jigframe, and a pin hole in which the fixing pin provided in the side homeposition jig is inserted may be formed in the docking bracket.

The brazing assembly may include: a brazing bracket mounted on thebrazing robot; a laser head that is installed at the brazing bracket andirradiates a laser beam to the bonding portions between the oppositeside panels and the roof panel; and a wire feeder that is provided inthe brazing bracket and supplies a filler wire to a focus position ofthe laser beam.

The gap measurement unit may include a profile sensor that is installedat the brazing bracket, scans matching portions between the oppositeside panels and the roof panel, and measures gaps of the matchingportions.

An operating cylinder may be fixedly installed at the brazing bracket,and a sensor bracket to which the profile sensor is fixed may beconnected to an operating rod of the operating cylinder.

The sensor bracket may include an air blower jetting air and an air jetpassage connected to the air blower, and the air is jetted in adirection perpendicular to an irradiation direction of the laser beamthrough the air jet passage.

The grinding assembly may include: a grinding bracket mounted on thegrinding robot; a grinding motor installed at the grinding bracket to bevertically movable; a grinding wheel coupled to a drive shaft of thegrinding motor; a moving plate that is connected to the drive shaft ofthe grinding motor through a bushing and is installed at the grindingbracket to be vertically movable; a wheel cover that is mounted on thegrinding bracket to cover the grinding wheel and at which an inletsucking grinding-dust particles scattered by the grinding wheel isinstalled; a pressure control cylinder that is fixedly installed at thegrinding bracket, is connected to the moving plate, and controls agrind-pressing force of the grinding wheel; and a stopper cylinder thatis fixedly installed at the grinding bracket and selectively limitsmovement of the moving plate.

A pair of rail blocks may be vertically installed at the grindingbracket, a guide groove vertically guiding the bushing may be formed inthe grinding bracket, the moving plate may be disposed between thegrinding bracket and the wheel cover, and a sliding block slidablycoupled to the rail block may be installed at the rail block.

The stopper cylinder may include an operating rod that passes throughthe grinding bracket and operates to move the moving plate forward orbackward, and a friction pad may be installed at the moving platecorresponding to a front end of the operating rod.

The roof laser brazing system may further include a bead inspection unitthat is installed at the grinding assembly, inspects brazing beadsground by the grinding assembly, and senses a position of the body,wherein the bead inspection unit may include: a mounting bracketinstalled at the grinding bracket; a vision camera that is installed atthe mounting bracket and vision-photographs the ground brazing bead; anda profile sensor that is installed at the mounting bracket and scans theground brazing bead to measure a height of the brazing bead.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings are intended to be used as references for describing theexemplary embodiments of the present disclosure, and the accompanyingdrawings should not be construed as limiting the technical spirit of thepresent disclosure.

FIG. 1 schematically illustrates a block diagram of a roof laser brazingsystem according to an exemplary embodiment of the present disclosure.

FIGS. 2 to 4 are drawings illustrating a side home position jig appliedto a roof laser brazing system according to an exemplary embodiment ofthe present disclosure.

FIG. 5 illustrates a perspective view of a damper of a side homeposition jig applied to a roof laser brazing system according to anexemplary embodiment of the present disclosure.

FIG. 6 illustrates a perspective view of a fixing pin of a side homeposition jig applied to a roof laser brazing system according to anexemplary embodiment of the present disclosure.

FIGS. 7 to 9 are drawings of illustrating a roof-pressing jig applied toa roof laser brazing system according to an exemplary embodiment of thepresent disclosure.

FIG. 10 illustrates a perspective view of a docking bracket of aroof-pressing jig applied to a roof laser brazing system according to anexemplary embodiment of the present disclosure.

FIG. 11 illustrates a perspective view of a vacuum cup of aroof-pressing jig applied to a roof laser brazing system according to anexemplary embodiment of the present disclosure.

FIG. 12 illustrates a perspective view of a restriction pin of aroof-pressing jig applied to a roof laser brazing system according to anexemplary embodiment of the present disclosure.

FIG. 13 illustrates a perspective view of a reference pin of aroof-pressing jig applied to a roof laser brazing system according to anexemplary embodiment of the present disclosure.

FIG. 14 illustrates a schematic diagram for a laser brazing principle ofa brazing assembly applied to a roof laser brazing system according toan exemplary embodiment of the present disclosure.

FIGS. 15 to 17 are drawings of illustrating a brazing assembly and a gapmeasurement unit that are applied to a roof laser brazing systemaccording to an exemplary embodiment of the present disclosure.

FIG. 18 is a drawing of illustrating an air jet structure for a brazingassembly applied to a roof laser brazing system according to anexemplary embodiment of the present disclosure.

FIGS. 19 and 20 illustrate a combined perspective views of a grindingassembly applied to a roof laser brazing system according to anexemplary embodiment of the present disclosure.

FIG. 21 illustrates an exploded perspective view of a grinding assemblyapplied to a roof laser brazing system according to an exemplaryembodiment of the present disclosure.

FIG. 22 illustrates an assembled cross-sectional view of a grindingassembly applied to a roof laser brazing system according to anexemplary embodiment of the present disclosure.

FIG. 23 illustrates a schematic diagram of a bead inspection unitapplied to a roof laser brazing system according to an exemplaryembodiment of the present disclosure.

DETAILED DESCRIPTION

The present disclosure will be described more fully hereinafter withreference to the accompanying drawings, in which exemplary embodimentsof the disclosure are shown. As those skilled in the art would realize,the described embodiments may be modified in various different ways, allwithout departing from the spirit or scope of the present disclosure.

FIG. 1 schematically illustrates a block diagram of a roof laser brazingsystem according to an exemplary embodiment of the present disclosure.

Referring to FIG. 1, a roof laser brazing system 100 according to anexemplary embodiment of the present disclosure restricts main buckassembly parts with a jig and welds them, and it may be applied to amain buck process of a vehicle body assembly line that assembles avehicle body.

Further, the roof laser brazing system 100 according to the exemplaryembodiment of the present disclosure may be applied to a process ofbonding a roof panel 5 to opposite side panels 3 based on a body 1including the opposite side panels 3 in the main buck process of thevehicle body assembly line.

Here, the body 1 may be one of which the opposite side panels 3 areassembled to a predetermined structure, for example, of which the sidepanels 3 are assembled to opposite sides of a floor panel (not shown).The body 1 may be transferred along a transfer line 7 by a carriage (notshown).

In the industry, a width direction of the body 1 is typically referredto as an L direction, a transfer direction of the body 1 as a Tdirection, and a height direction of the body 1 as an H direction.However, in the exemplary embodiment of the present disclosure,references to the directions are not set according to the LTH directionsbut are set as a width direction, a transfer direction, and a heightdirection of the body.

The roof laser brazing system 100 according to the exemplary embodimentof the present disclosure is configured in a structure in which portionsat which the opposite side panels 3 and the roof panel 5 of the body 1are bonded together by a laser-brazing method so that a roof molding maybe removed.

Further, the roof laser brazing system 100 according to the exemplaryembodiment of the present disclosure may be configured in apredetermined brazing section 8 and a predetermined grinding section 9along a transfer path of the body 1.

For example, the roof laser brazing system 100 according to theexemplary embodiment of the present disclosure may bond the bondingportions between the opposite side panels 3 and the roof panel 5 of thebody 1 by the laser-brazing method in the brazing section 8.

In addition, the roof laser brazing system 100 according to theexemplary embodiment of the present disclosure may grind brazing beadsof the brazing portions between the opposite side panels 3 and the roofpanel 5 in the grinding section 9.

For this purpose, the roof laser brazing system 100 according to theexemplary embodiment of the present disclosure may include side homeposition jigs 200, a roof-pressing jig 300, a brazing assembly 400, agap measurement unit 500, a grinding assembly 600, and a bead inspectionunit 700.

The above-described components may be totally installed in one processframe in the vehicle body assembly line of the main buck process, or maybe separately installed in divided process frames therein.

In the exemplary embodiment of the present disclosure, the side homeposition jigs 200 are provided to restrict the opposite side panels 3 ofthe body 1 so that the opposite side panels 3 are positioned atpredetermined positions, which are configured in the brazing section 8and are installed at opposite sides of a transfer path of the body 1.

The side home position jigs 200, based on a body 1 of a predeterminedtype of vehicle that is transferred to the brazing section 8 by thetransfer path of the transfer line 7, may clamp the opposite side panels3 of the body 1 and may position the opposite side panels 3 at apredetermined position, which is a home position.

Further, the side home position jigs 200 may restrict the opposite sidepanels 3 to correspond to bodies 1 of different kinds of vehicles, andthey may home-position the opposite side panels 3 at a predeterminedposition depending on a gap value between the side panels 3 and the roofpanel 5 measured by a gap measurement unit 500 which will be describedin detail later.

Here, the term, “home position” may be defined as a position at whichthe gap between the side panels 3 and the roof panel 5 becomes zerowhile the opposite side panels 3 are flowingly moved by the side homeposition jigs 200 in the width direction of the body 1.

For example, the side home position jigs 200 restrict the opposite sidepanels 3 and home-position the opposite side panels 3 depending on thegap value measured by the gap measurement unit 500, thereby ensuring azero gap between the opposite side panels 3 and the roof panel 5. Inaddition, the term, “restriction” may be defined as clamping theopposite side panels 3.

In the exemplary embodiment of the present disclosure, the side homeposition jigs 200 are provided at the opposite sides of the transferpath with the transfer path of the body 1 therebetween. However, onlyone side home position jig 200 installed at one side of the transferpath will now be described.

FIGS. 2 and 3 illustrate perspective view of a side home position jigapplied to a roof laser brazing system according to an exemplaryembodiment of the present disclosure, and FIG. 4 illustrates a sideschematic diagram of a side home position jig applied to a roof laserbrazing system according to an exemplary embodiment of the presentdisclosure.

Referring to FIGS. 2 to 4, a side home position jig 200 according to theexemplary embodiment of the present disclosure includes a base frame210, a moving frame 220, a post frame 230, a support frame 240, andclampers 250.

The base frame 210 is provided to support the moving frame 220, the postframe 230, and the support frame 240, and is installed at the oppositesides of the transfer path with the transfer path of the body 1therebetween in the brazing section 8.

The base frame 210 includes sub-elements such as various brackets,support blocks, plates, housings, covers, collars, and the like forsupporting the moving frame 220. However, because the sub-elements areto install the moving frame 220 in the base frame 210, except for anexceptional case, the sub-elements are generally referred to as the baseframe 210 in the exemplary embodiment of the present disclosure.

The moving frame 220 is installed at the base frame 210 to bereciprocally movable in the width direction of the body 1. The movingframe 220 is installed to be slidingly movable on a plurality of guiderails 221 provided in the base frame 210.

The guide rails 221 are spaced apart from each other by a predetermineddistance along the transfer direction of the body 1, are installed on atop surface of the base frame 210, and are extendedly disposed in thewidth direction of the body 1. Sliders 223 are installed on a bottomsurface of the moving frame 220. Each slider 223 is slidably coupled toa guide rail 221.

Here, a first driving part 225 for reciprocally moving the moving frame220 in the width direction of the body 1 is installed at the base frame210. The first driving part 225 is configured to be able to convertrotational motion of a motor into linear motion of the moving frame 220.

The first driving part 225 includes a first servo motor 227 that isinstalled at the base frame 210 and a lead screw 229 that is connectedto the first servo motor 227 and is substantially screw-fixed to themoving frame 220.

The first servo motor 227 may be fixedly mounted on a top surface of thebase frame 210. The lead screw 229 may be connected to a drive shaft ofthe first servo motor 227, and may be screw-fixed to a predeterminedblock (not shown) fixed to the bottom surface of the moving frame 220.

The post frame 230 is installed at each of the opposite sides of themoving frame 220 along the transfer direction of the body 1, and it isfixedly mounted in a vertical direction of the moving frame 220.

As a frame for substantially supporting clampers 250 that will bedescribed later, the support frame 240 is extendedly disposed along alength direction of the opposite side panels 3, that is, along thetransfer direction of the body 1, and is connected to the post frame230.

The clampers 250 are provided to restrict the opposite side panels 3 andto home-position the opposite side panels 3 based on the gap valuemeasured by the gap measurement unit 500.

The clampers 250 are provided in plural, mounted on the support frame240 along the transfer direction of the body 1, and are installed to bereciprocally movable in the width direction of the body 1.

As a clamper for restricting upper sides of the opposite side panels 3,the damper 250, as shown in FIG. 5, may be operated by a clamp cylinder251 and may clamp the upper sides of the opposite side panels 3. Sincethe clamper 250 is configured as a clamping device based on well-knowndisclosed technologies in the art, a detailed description thereof willbe omitted in the present specification.

As described above, the clamper 250 is installed to be reciprocallymovable in the width direction of the body 1 at the support frame 240,and for this purpose, a second driving part 253 for reciprocally movingthe damper 250 in the width direction of the body 1 is provided in thesupport frame 240.

The second driving part 253 includes a second servo motor 255 that isinstalled at the support frame 240 and a linear motion (LM) guide 257that is connected to the second servo motor 255 and fixes the clamper250.

The second servo motor 255 is fixedly installed at the support frame240. The LM guide 257 receives torque of the second servo motor 255 andreciprocally moves the clamper 250 in the width direction of the body 1by the received torque.

The LM guide 257 may be connected to the second servo motor 255 througha power transmission unit such as a belt or a gear. The LM guide 257includes a ball screw 256 connected to the drive shaft of the secondservo motor 255, a moving block 258 screw-fixed to the ball screw 256and connected to the damper 250, and a rail member 259 slidably coupledto the moving block 258.

The clamper 250 may be linearly and reciprocally moved in the widthdirection of the body 1 through the LM guide 257 by rotating the secondservo motor 255 in a forward or reverse direction.

As such, the reason that the clamper 250 is configured to bereciprocally movable in the width direction of the body 1 through thesecond driving part 253 is to flowingly move the opposite side panels 3in the width direction of the body 1 in a state of restricting theopposite side panels 3 through the damper 250.

For example, in the state of restricting the opposite side panels 3, thedamper 250 may flowingly move the opposite side panels 3 in the widthdirection of the body 1 through the second driving part 253 depending onthe gap value measured by the gap measurement unit 500 such that the gapbetween the side panels 3 and the roof panel 5 may be zero.

In the present exemplary embodiment, as described above, the movingframe 220 being configured to be reciprocally movable in the widthdirection of the body 1 through the first driving part 225 moves theclampers 250 at predetermined positions corresponding to bodies 1 ofdifferent kinds of vehicles.

Further, in the present exemplary embodiment, the support frame 240 onwhich the clampers 250 is mounted may be rotatably installed at the postframe 230 through a drive motor 241.

The support frame 240 is rotatably supported by the post frame 230 andmay be rotated by the drive motor 241. The drive motor 241 may befixedly installed to the post frame 230 through a bracket.

The reason that the support frame 240 is configured to be rotatablyinstalled at the post frame 230 through the drive motor 241 is toselectively use different structures of dampers 250 corresponding tobodies 1 of different kinds of vehicles depending on the correspondingvehicle.

Here, the dampers 250 may have different structures corresponding to thebodies 1 of respective kinds of vehicles to be able to respectivelyrestrict the opposite side panels 3 of different kinds of vehicles, andmay be installed at any side or at least one side of the support frame240.

For example, the clampers 250 corresponding to one kind of vehicle areinstalled at one side of the support frame 240 along the transferdirection of the body 1, and the dampers 250 corresponding to each ofdifferent kinds of vehicles may be installed at another side of thesupport frame 240 along the transfer direction of the body 1.

In addition, since the support frame 240 is rotated by the drive motor241, the dampers 250 of different structures corresponding to the bodies1 of different kinds of vehicles are disposed at the side of oppositeside panels 3 of the corresponding kind of vehicle.

Further, as shown in FIG. 6, a support bracket 233 for docking with aroof-pressing jig 300 (refer to FIG. 1) that will be further describedlater is installed at each post frame 230.

A fixing pin 235 that is coupled to the roof-pressing jig 300 to fix theroof-pressing jig 300 is installed at the support bracket 233. Thefixing pin 235 may be inserted into a docking portion of theroof-pressing jig 300 with respect to the support bracket 233.

A pin damper 237 restricting a pin connection portion of theroof-pressing jig 300, that is, the docking portion, is installed at thesupport bracket 233 of the post frame 230. In the state in which thefixing pin 235 is coupled to the docking portion of the roof-pressingjig 300, the pin clamper 237 may restrict the fixing pin 235 togetherwith the pin connection portion of the roof-pressing jig.

Here, the pin damper 237 may rotate depending on an operation of a pinclamping cylinder 238, and may restrict the fixing pin 235 together withthe pin connection portion of the roof-pressing jig 300 by an operatingpressure of the pin clamping cylinder 238.

Referring to FIG. 1, in the exemplary embodiment of the presentdisclosure, the roof-pressing jig 300 is provided to home-position theroof panel 5 loaded on the opposite side panels 3 of the body 1 and topress the roof panel 5 with a handling robot 301. The roof-pressing jig300 is detachably installed at the handling robot 301, and is configuredto be able to be docked to the aforementioned side home position jig200.

Here, the roof panel 5 may be aligned in a roof alignment jig 101,unloaded from the roof alignment jig 101 by a roof loading jig 103, andloaded on the opposite side panels 3 of the body 1.

The roof alignment jig 101 aligns the roof panel 5 at a predeterminedposition, and is installed between the brazing section 8 and thegrinding section 9. The roof loading jig 103 is detachably installed atthe aforementioned handling robot 301.

The roof alignment jig 101 includes a reference pin holding a referenceposition of the roof panel 5 and retainers supporting edges of the roofpanel 5. The roof loading jig 103 includes a reference pin holding thereference position of the roof panel 5 and clampers restricting theedges of the roof panel 5.

Since configurations of the roof alignment jig 101 and the roof loadingjig 103 are well known in the art, a detailed description thereof willbe omitted in the present specification.

The handling robot 301 may tool-change the roof loading jig 103, theroof-pressing jig 300, and a spot-welding gun (not shown) through atool-changer.

Reference number 105, which is shown in FIG. 1, denotes a welding robotin which the spot welding gun is mounted and which spot-welds the roofpanel 5 and the front and rear roof rails, and the welding robot 105 isprovided in the brazing section 8.

FIGS. 7 to 9 are drawings illustrating a roof-pressing jig applied to aroof laser brazing system according to an exemplary embodiment of thepresent disclosure.

Referring to FIGS. 7 to 9, a roof-pressing jig 300 according to theexemplary embodiment of the present disclosure includes a jig frame 310,a restriction pad 320, vacuum cups 330, a restriction pin 340, and areference pin 360.

The jig frame 310 is detachably installed at an arm end of the handlingrobot 301. The jig frame 310 includes a main frame 311 and a sub-frame313 integrally connected to a front end and a rear end of the main frame311.

The main frame 311 is formed in a shape of a ladder, and includes arobot coupling part 315 combined with the arm end of the handling robot301. The sub-frame 313 is formed in a ‘-’-shape, and is disposed at thefront and rear ends of the main frame 311 along a left/right direction(width direction of the body).

Here, docking brackets 317 docked to the support bracket 233 of theaforementioned side home position jig 200 are fixedly installed atopposite sides of each of the front and rear jig frames 310, that is, atopposite sides of each sub-frame 313. A rubber pad 318 is installed atthe bottom surface of the docking bracket 317. When the docking bracket317 is docked to the support bracket 233, the rubber pad 318 serves tobuffer impact of the docking bracket 317 with respect to the supportbracket 233.

As shown in FIG. 10, a pin hole 319 into which the fixing pin 235 of theside home position jig 200 is inserted is formed in the docking bracket317. For example, when the docking bracket 317 is docked to the supportbracket 233 of the side home position jig 200, the fixing pin 235 iscombined with the pin hole 319 of the docking bracket 317.

The “docking” may be defined as a state in which the docking bracket 317is positioned at the support bracket 233 when the roof-pressing jig 300home-positions and presses the roof panel 5.

The restriction pad 320 supports the roof panel 5 loaded on the oppositeside panels 3 of the body 1 and the opposite side edges of the roofpanel 5 along the length direction of opposite side panels 3.

The restriction pad 320 is fixedly installed at each of the left andright sides of the main frame 311 of the jig frame 310, and is disposedalong a length direction of the main frame 311. The restriction pad 320is formed in a shape corresponding to the roof panel 5.

The restriction pad 320 is made of an aluminum material with excellentthermal conductivity so that the opposite side panels 3 and the roofpanel 5 may not be overheated when they are bonded by laser brazing.

The vacuum cups 330 vacuum-adsorbs a skin surface of the opposite sideedges of the roof panel 5, and is installed at the main frame 311 of thejig frame 310 corresponding to the restriction pad 320.

As shown in FIG. 11, the vacuum cups 330 pass through a plurality ofpenetration holes 325 that are continuously formed in the restrictionpad 320 along the opposite side edges of the roof panel 5, and mayvacuum adsorb the skin surface of the opposite side edges of the roofpanel 5.

The vacuum cups 330 are installed to be spaced apart from each other inthe main frame 311 of the jig frame 310 along the length direction ofthe main frame 311, and are installed through a fixing bracket 331 fixedto the main frame 311.

Here, a mounting rod 333 is fixedly installed at the fixing bracket 331.An upper end of the mounting rod 333 is fixed to the fixing bracket 331,and a lower end of the mounting rod 333 is disposed in a penetrationhole 325 of the restriction pad 320. The vacuum cup 330 is installed atthe lower end of the mounting rod 333. The vacuum cup 330 may beconnected to the lower end of the mounting rod 333 through a spring 335.

As shown in FIG. 12, when the roof panel 5 is restricted through therestriction pad 320 and the vacuum cups 330, the restriction pin 340 isinserted into a restriction hole 6 a formed in the roof panel 5 from anupper side thereof to a lower side thereof for restricting the roofpanel 5. The restriction pin 340 is installed to be vertically movableat the main frame 311 of the jig frame 310 in a front end side of therestriction pad 320.

A restriction pin cylinder 341 is installed at the jig frame 310 so thatthe restriction pin 340 may be vertically reciprocally moved. Therestriction pin cylinder 341 is connected to the restriction pin 340,and is fixedly installed at the main frame 311 of the jig frame 310.

The restriction pin cylinder 341 includes a restriction pin-operatingrod 343 that is moved forward or backward by pneumatic pressure orhydraulic pressure. A restriction bracket 345 for supporting the bottomsurface of the roof panel 5 and fixing the restriction pin 340 isinstalled at the restriction pin-operating rod 343. The restrictionbracket 345 includes a flat top surface. The restriction pin 340 isfixedly installed at the top surface of the restriction bracket 345.

Accordingly, in the present exemplary embodiment, when the restrictionpin-operating rod 343 of the restriction pin cylinder 341 upwardly movesbackward in a state in which it has downwardly moved forward, the bottomsurface of the roof panel 5 may be supported by the restriction bracket345, and at the same time, the restriction pin 340 may be inserted intothe restriction hole 6 a of the roof panel 5 to restrict the roof panel5.

As shown in FIG. 13, when the roof panel 5 is restricted through therestriction pad 320, the vacuum cups 330, and the restriction pin 340,the reference pin 360 is inserted into a reference hole 6 b formed inthe roof panel 5 from a lower side thereof to an upper side thereof. Thereference pin 360 is installed to be vertically movable at the mainframe 311 of the jig frame 310 in a rear end side of the restriction pad320.

A reference pin cylinder 361 is installed at the jig frame 310 so thatthe reference pin 360 may be vertically reciprocally moved. Thereference pin cylinder 361 is connected to the reference pin 360, and isfixedly installed at the main frame 311 of the jig frame 310.

The reference pin cylinder 361 includes a reference pin-operating rod363 that is moved forward or backward by pneumatic pressure or hydraulicpressure. The reference pin 360 is installed at the referencepin-operating rod 363.

Accordingly, in the present exemplary embodiment, while the roof panel 5is restricted through the restriction pad 320, the vacuum cups 330, andthe restriction pin 340, when the reference pin-operating rod 363 of thereference pin cylinder 361 downwardly moves forward in a state in whichthe reference pin-operating rod 363 of the reference pin cylinder 361has upwardly moved backward, the reference pin 360 may be inserted intothe reference hole 6 b of the roof panel 5 to hold a reference positionof the roof panel 5.

As shown in FIGS. 1 and 14, in the exemplary embodiment of the presentdisclosure, the brazing assembly 400 brazes the bonding portions betweenthe opposite side panels 3 and the roof panel 5 that are closely pressedto each other by the roof-pressing jig 300 while using a laser which isa heating source.

The brazing assembly 400 is installed at each of a pair of brazingrobots 401 in the side home position jig 200 side of the brazing section8. A brazing robot 401 is installed at each of the side home positionjigs 200 side with the transfer path of the body 1 therebetween.

Here, the brazing assembly 400 may melt a filler metal by using a laseras a heating source, and may braze the bonding portions between theopposite side panels 3 and the roof panel 5.

For example, the brazing assembly 400 may irradiate continuous waveNd:YAG laser beams 403 oscillated by a laser oscillator to the bondingportions between the opposite side panels 3 and the roof panel 5 to melta filler wire 405 of the filler metal, thereby brazing the bondingportions between the opposite side panels 3 and the roof panel 5.

FIGS. 15 to 17 are drawings illustrating a brazing assembly and a gapmeasurement unit that are applied to a roof laser brazing systemaccording to an exemplary embodiment of the present disclosure.

Referring to FIGS. 15 to 17, a brazing assembly 400 according to theexemplary embodiment of the present disclosure includes a brazingbracket 410, a laser head 430, and a wire feeder 450.

The brazing bracket 410 is installed at the arm front end of the brazingrobot 401. The brazing bracket 410 is provided to be rotatable by thebrazing robot 401, and may be transferred along the bonding portionsbetween the opposite side panels 3 and the roof panel 5 by the brazingrobot 401.

The brazing bracket 410 is directly mounted on the arm of the brazingrobot 401 by considering characteristics of the laser head 430 that issusceptible to an external factor such as vibration. The brazing bracket410 is substantially formed in a “⊏”-shape, and includes reinforcingplates 411 installed at the edges thereof for reducing weakness of theedges thereof.

The laser head 430 irradiates laser beams to the bonding portionsbetween the opposite side panels 3 and the roof panel 5, and isinstalled at the brazing bracket 410. The laser head 430 may be a Nd:YAGoptical head irradiating continuous wave Nd:YAG laser beams oscillatedby a laser oscillator controlled by a controller along the bondingportions between the opposite side panels 3 and the roof panel 5.

Here, the laser oscillated by the laser oscillator is irradiated to thebonding portions between the opposite side panels 3 and the roof panel 5from the laser head 430 in a state of being focused by an opticalsystem.

The wire feeder 450 feeds the filler wire 405 of the filler metal to afocus position of the laser beam that is irradiated from the laser head430. The wire feeder 450 is provided in the brazing bracket 410.

Since the laser head 430 and the wire feeder 450 are configured as alaser optical head device and a wire feeder based on the well-knowndisclosed technologies in the art, a detailed description thereof willbe omitted in the present specification.

Referring to FIG. 1 and FIGS. 15 to 17, a gap measurement unit 500according to an exemplary embodiment of the present disclosure measuresmatching gaps between the roof panel 5 and the opposite side panels 3that are pressed by the roof-pressing jig 300 before laser-brazing theopposite side panels 3 and the roof panel 5 through the laser head 430and the wire feeder 450 of the brazing assembly 400.

The gap measurement unit 500 measures the matching gaps between the roofpanel 5 and the opposite side panels 3 pressed by the roof-pressing jig300 and outputs the measured values to a controller (not shown).

Here, the controller may control an operation of the side home positionjig 200 depending on the matching gap values between the roof panel 5and the opposite side panels 3 measured by the gap measurement unit 500.

For example, the controller applies a control signal to the seconddriving part 253 of the side home position jig 200 depending on the gapvalues between the roof panel 5 and the opposite side panels 3 measuredby the gap measurement unit 500 to be able to move the clampers 250 ofthe side home position jig 200 restricting the opposite side panels 3 inthe width direction of the body 1.

Accordingly, in the exemplary embodiment of the present disclosure,based on the gap values between the roof panel 5 and the opposite sidepanels 3 measured by the gap measurement unit 500, it is possible toflowingly move and home-position the opposite side panels 3 in the widthdirection of the body 1 through the side home position jig 200, and thegaps between the opposite side panels 3 and the roof panel 5 may bezero.

The gap measurement unit 500 is installed at the brazing bracket 410 ofthe brazing assembly 400. The gap measurement unit 500 includes a firstprofile sensor 510 that scans matching portions between the oppositeside panels 3 and the roof panel 5 and measures gaps of the matchingportions.

The first profile sensor 510 scans the matching portions between theopposite side panels 3 and the roof panel 5 with a laser slit, andmeasures the gaps of the matching portions. For example, the firstprofile sensor 510 sets a virtual reference line based on astraight-line portion of the roof panel 5, and calculates a distancebetween profiles generated on the virtual reference line, therebymeasuring the matching gaps between the roof panel 5 and the oppositeside panels 3.

Since the profile sensor is configured as a profile sensor based on thewell-known disclosed technologies, a detailed description thereof willbe omitted in the present specification.

Here, the first profile sensor 510 is installed at the brazing bracket410 of the brazing assembly 400 side through a sensor bracket 511. Thesensor bracket 511 fixes the first profile sensor 510, and is installedto be able to be moved forward or backward with respect to the brazingbracket 410.

For this purpose, an operating cylinder 520 is fixedly installed at thebrazing bracket 410. The operating cylinder 520 includes an operatingrod 521 that is moved forward or backward by a pneumatic pressure or ahydraulic pressure operating rod 521. The sensor bracket 511 to whichthe first profile sensor 510 is fixed is connected to a front end of theoperating rod 521. Accordingly, the sensor bracket 511 may be movedforward or backward by the operating cylinder 520.

In addition, a pair of guide bars 525 for guiding the sensor bracket 511that is moved forward or backward by the operating rod 521 is installedat the operating cylinder 520. A guide bar 525 is slidably inserted in abody of the operating cylinder 520, and is coupled to a front end of theoperating rod 521 through a fixing block 527. The fixing block 527connects the front end of the operating rod 521 and a front end (lowerend in the drawing) of the guide bar 525, and is fixed to the sensorbracket 511.

The sensor bracket 511 may move forward through the operating cylinder520 to measure the matching gaps between the roof panel 5 and theopposite side panels 3 through the first profile sensor 510, beforelaser-brazing the opposite side panels 3 and the roof panel 5 throughthe brazing assembly 400.

When the opposite side panels 3 and the roof panel 5 are laser-brazed bythe brazing assembly 400, the sensor bracket 511 is moved backward bythe operating cylinder 520, thereby preventing interference with thebrazing assembly 400.

As shown in FIG. 18, when the opposite side panels 3 and the roof panel5 are laser-brazed by the brazing assembly 400, an air blower 550, whichjets air into the brazing portions between the opposite side panels 3and the roof panel 5, is installed in the sensor bracket 511.

That is, the air blower 550 jets air to the brazing portion sidesbetween the opposite side panels 3 and the roof panel 5 to prevent aforeign material from being attached to the laser-brazing portionsbetween the opposite side panels 3 and the roof panel 5.

The air blower 550 receives air of a predetermined pressure supplied byan air compressor (not shown) to be able to jet the air into the brazingportions between the opposite side panels 3 and the roof panel 5.

For example, the air blower 550 may jet air in a direction perpendicularto the irradiated direction of the laser beam irradiated from the laserhead 430 of the brazing assembly 400.

For this purpose, an air jet passage 555 connected to the air blower 550is formed in the sensor bracket 511. The air jet passage 555 is formedalong the irradiated direction of the laser beam irradiated from thelaser head 430, and is provided with a passage opened in the directionperpendicular to the irradiated direction of the laser beam.

Referring to FIG. 1, in the exemplary embodiment of the presentdisclosure, the grinding assembly 600 grinds brazing beads (not shown)of the brazing portions between the opposite side panels 3 and the roofpanel 5 that are laser-brazed by the brazing assembly 400.

The grinding assembly 600 may grind the brazing beads in a state inwhich the opposite side panels 3 and the roof panel 5 are completelylaser-brazed by the brazing assembly 400 in the brazing section 8 of thebody transfer path and then the body 1 is transferred in the grindingsection 9 along the body transfer path.

Here, the grinding assembly 600 is provided in each of a pair ofgrinding robots 601 in the grinding section 9 of the body transfer path.The grinding robots 601 are respectively installed at opposite sides ofthe transfer path of the body 1 with the transfer path of the body 1therebetween.

In this case, the grinding assembly 600 may be moved along apredetermined teaching path by a grinding robot 601, and may grind thebrazing beads of the brazing portions of the opposite side panels 3 androof panel 5.

FIGS. 19 and 20 illustrate a combined perspective views of a grindingassembly applied to a roof laser brazing system according to anexemplary embodiment of the present disclosure, FIG. 21 illustrates anexploded perspective view of a grinding assembly applied to a roof laserbrazing system according to an exemplary embodiment of the presentdisclosure, and FIG. 22 illustrates an assembled cross-sectional view ofa grinding assembly applied to a roof laser brazing system according toan exemplary embodiment of the present disclosure.

Referring to FIG. 1 and FIGS. 19 to 22, a grinding assembly 600according to an exemplary embodiment of the present disclosure includesa grinding bracket 610, a grinding motor 620, a grinding wheel 630, awheel cover 640, a moving plate 650, a pressure control cylinder 660,and a stopper cylinder 670.

The grinding bracket 610 is mounted on an arm front end of the grindingrobot 601 to be rotatable by the grinding robot 601, and may betransferred along the bonding portions between the opposite side panels3 and the roof panel 5 by the grinding robot 601.

The grinding motor 620 rotates the grinding wheel 630 that will befurther described later, and is installed to be movable in a verticaldirection of the grinding bracket 610 with reference to the drawing.

The grinding wheel 630 is provided to grind the brazing beads of thelaser-brazed opposite side panels 3 and roof panel 5. The grinding wheel630 is formed in a disc shape, and may be coupled to a drive shaft 621of the grinding motor 620 to be rotated.

The wheel cover 640, which covers the grinding wheel 630, serves tocollect grinding-dust particles scattered when the brazing beads of thebonding portions of the opposite side panels 3 and roof panel 5 areground through the grinding wheel 630 without disturbing verticalmovement of the grinding motor 620.

The wheel cover 640 is formed as a housing, a lower portion of which isopened while it wholly surrounds the grinding wheel 630 coupled to thedrive shaft 621 of the grinding motor 620, and is fixedly mounted on thegrinding bracket 610.

Here, the grinding wheel 630 is rotated by the grinding motor 620 insidethe wheel cover 640, and may grind the brazing beads through the loweropened portion of the wheel cover 640.

A first guide groove 641 guiding the vertical movement of the grindingmotor 620 to not disturb the vertical movement of the grinding motor 620is formed in the wheel cover 640. The first guide groove 641 is formedin one surface of the wheel cover 640 fixed to the grinding bracket 610in the upper direction from the lower opened portion of the wheel cover640.

Further, an inlet 645 for sucking the grinding-dust particles scatteredwhen the brazing beads of the bonding portions of the opposite sidepanels 3 and roof panel 5 are ground through the grinding wheel 630, isinstalled at the wheel cover 640.

The inlet 645 sucks the grinding-dust particles scattered inside thewheel cover 640 and exhausts them outside the wheel cover 640 and, forexample, may be connected to a vacuum pump (not shown) through a dustparticle exhaust line (not shown).

The moving plate 650, which supports the grinding motor 620 with respectto the grinding bracket 610 and guides the vertical movement of thegrinding motor 620, is installed between the grinding bracket 610 andthe wheel cover 640.

The moving plate 650 is connected to the drive shaft 621 of the grindingmotor 620 through a bushing 651, and is installed to be movable in thevertical direction of the grinding bracket 610.

The bushing 651, which is installed at the drive shaft 621 of thegrinding motor 620 and rotatably supports the drive shaft 621, isprovided as a rotational supporter of a cylindrical shape.

For the vertical movement of the moving plate 650 as described above, apair of rail blocks 653 are installed at one surface of the grindingbracket 610 corresponding to the moving plate 650. In addition, a pairof sliding blocks 655 that are slidably coupled to the rail blocks 653are installed at one surface of the moving plate 650 corresponding tothe rail blocks 653.

Here, since the grinding motor 620 is connected to the moving plate 650through the bushing 651 on the drive shaft 621, it may move in thevertical direction with respect to the grinding bracket 610 through therail blocks 653 and the sliding blocks 655.

For example, the grinding motor 620 may be downwardly moved by its ownweight and be upwardly moved by a predetermined external force, andlowermost and uppermost movement positions of the grinding motor 620 maybe determined by a separate stopper, for example, by a stopperprotrusion provided at the upper and lower side of the rail blocks 653.

A second guide groove 615 for vertically guiding the bushing 651 to notdisturb the vertical movement of the grinding motor 620 is formed in thegrinding bracket 610.

The second guide groove 615 is formed to upwardly extend from a lowerside of one surface the grinding bracket 610 corresponding to the movingplate 650 to be able to vertically guide the bushing 651 on the driveshaft 621 of the grinding motor 620.

The pressure control cylinder 660 controls a grind-pressing force of thegrinding wheel 630 with respect to the brazing beads of the brazingportions of the opposite side panels 3 and the roof panel 5.

The pressure control cylinder 660 is fixedly installed at the grindingbracket 610, and is connected to the moving plate 650. The pressurecontrol cylinder 660 is mounted on an upper end of the grinding bracket610 through a mounting bracket 661, and may be connected to the movingplate 650 through a pressure control rod 663.

The pressure control cylinder 660, which is a proportional pressurecontroller to be controllable at a pressure of about 0 bar to 10 bar,may control the grind-pressing force of the grinding wheel 630 withrespect to the brazing bead by applying a predetermined pneumaticpressure to the pressure control rod 663 depending on a voltage and acurrent.

The stopper cylinder 670 selectively limits the vertical movement of themoving plate 650, and is fixedly installed at the grinding bracket 610.That is, the stopper cylinder 670 limits the vertical movement of thegrinding motor 620 by its own weight and the external force, asdescribed above.

The stopper cylinder 670 includes a stopper-operating rod 671 thatpasses through the grinding bracket 610 to operate forward or backwardwith respect to the moving plate 650. Accordingly, a penetration hole673 through which the stopper-operating rod 671 passes in a portion atwhich the stopper cylinder 670 is installed is formed in the grindingbracket 610.

A friction pad 675 is installed at one surface of the moving plate 650corresponding to a front end of the stopper-operating rod 671. Thefriction pad 675 closely contacts the front end of the stopper-operatingrod 671, thereby limiting the vertical movement of the grinding motor620 by its own weight and the external force. For example, the frictionpad 675 may be made of a plastic material such as Teflon.

As described above, the reason that the grinding motor 620 may bevertically moved by its own weight and the vertical movement of theexternal force and that the grinding motor 620 by its own weight and theexternal force may be limited by the stopper cylinder 670 is to reduceabrasion of the grinding wheel 630 when the brazing beads are ground bythe grinding wheel 630.

Further, since the grinding assembly 600 is moved along a predeterminedteaching path by the grinding robot 601 and the brazing beads are groundby the grinding wheel 630, a grinding surface of the grinding wheel 630should always grind the brazing beads at a predetermined position.

However, when the grinding wheel 630 is newly installed at the grindingmotor 620, the grinding surface of the grinding wheel 630 is positionedat a lower position than that of the brazing bead.

In this case of the exemplary embodiment of the present disclosure, themoving plate 650 together with the grinding wheel 630 moves the grindingmotor 620 upwardly and positions the grinding surface of the grindingwheel 630 at the predetermined position by exerting an external force tothe grinding wheel 630 through a separate supporter 603. In addition,the movement of the grinding motor 620 is limited by the stoppercylinder 670, and the grinding motor 620 may be fixed to a predeterminedposition of the grinding surface of the grinding wheel 630.

In contrast, when abrasion of the grinding wheel 630 occurs while thebrazing beads are ground by the grinding wheel 630, the grinding surfaceof the grinding wheel 630 is positioned at a higher position than thatof the brazing bead.

In this case, when the movement limit of the grinding motor 620 isreleased through the stopper cylinder 670, the grinding motor 620 isdownwardly moved by its own weight together with the grinding wheel 630,and the grinding surface of the grinding wheel 630 is positioned at apredetermined position by the supporter 603. In addition, the movementof the grinding motor 620 is limited by the stopper cylinder 670, andmay be fixed to the predetermined position of the grinding surface ofthe grinding wheel 630.

The stopper cylinder 670 may be operated through a sensor (not shown)that senses the grinding surface based on the predetermined position ofthe grinding surface with respect to the grinding wheel 630.

Referring to FIG. 1 and FIGS. 19 to 22, a bead inspection unit 700 isprovided to inspect the brazing beads ground by the grinding assembly600 in the exemplary embodiment of the present disclosure. That is, thebead inspection unit 700 automatically inspects for defects of thebrazing beads ground by the grinding assembly 600.

The bead inspection unit 700 is installed at the grinding assembly 600,and may be transferred along the ground brazing beads of the brazingportions of the opposite side panels 3 and the roof panel 5 by thegrinding robot 601.

As shown in FIG. 23, the bead inspection unit 700 includes a mountingbracket 710, a vision camera 730, and a second profile sensor 750.

The mounting bracket 710 is fixedly installed at the grinding bracket610 of the grinding assembly 600. The mounting bracket 710 may rotatetogether with the grinding bracket 610 by the grinding robot 601.

The vision camera 730, which vision-photographs the ground brazing beadsand outputs the vision-photographed data to the aforementionedcontroller, is fixedly installed to the mounting bracket 710.

Here, a lighting unit 731 irradiating light to the ground brazing beadsis installed at the mounting bracket 710. The lighting unit 731 isfixedly installed at the mounting bracket 710 in a vision-photographingarea of the vision camera 730.

The controller may calculate a width, etc. of the ground brazing bead byanalyzing the vision data transmitted from the vision camera 730, andmay detect a defect of the ground brazing bead by comparing thecalculated value with a reference value of the ground brazing bead.

The vision camera 730 vision-photographs a predetermined reference pointof the body 1 such as a front glass-mounting hole and a brazing portionof a center pillar side before the brazing beads are ground by thegrinding assembly 600, and may output the vision-photographed data tothe controller. That is, the vision camera 730 may detect a position ofthe body 1 before the brazing beads are ground by the grinding assembly600.

The controller may calculate a position value of the body 1 by analyzingthe vision data transmitted from the vision camera 730, and may detectthe defect of the ground brazing bead by comparing the calculated valuewith a reference position value of the body.

The second profile sensor 750, which scans the ground brazing bead tomeasure a height, etc. of the ground brazing bead, is fixedly installedat the mounting bracket 710 together with the vision camera 730.

The second profile sensor 750 may scan the ground brazing bead with alaser slit, and may measure the height, etc. of the brazing bead. Forexample, the second profile sensor 750 detects a cross-section of theground brazing bead as a 2-dimentional profile shape, and outputs thedetected signal to the controller.

The controller may calculate a height, etc. of the ground brazing beadby analyzing the detected signal transmitted from the second profilesensor 750, and may detect the defect of the ground brazing bead bycomparing the calculated value with a reference value of the groundbrazing bead.

Since the profile sensor is configured as a profile sensor based on thewell-known disclosed technologies in the art, a detailed descriptionthereof will be omitted in the present specification.

Here, a beam through hole 717 passing a scan beam (laser slit)irradiated from the second profile sensor 750 therethrough is formed inthe mounting bracket 710.

Operation of the roof laser brazing system according to the exemplaryembodiment of the present disclosure will now be described in detailwith reference to aforementioned drawings.

First, in the exemplary embodiment of the present disclosure, the body1, the opposite side panels 3 of which are assembled to thepredetermined structure, is transferred to the side home position jig200 of the brazing section 8 along the transfer line 7 by the carriage(not shown) in the main buck process of the vehicle body assembly line.

Here, the moving frame 220 of the side home position jig 200 has beenmoved away from the opposite side panels 3 of the body 1 along the widthdirection of the body 1 by the first driving part 225.

That is, the clambers 250 installed at the support frame 240 by the postframe 230 on the moving frame 220 have been moved away from the oppositeside panels 3 of the body 1 by the moving frame 220.

In the exemplary embodiment of the present disclosure, the support frame240 is rotated by the drive motor 214, and the dampers 250 correspondingto the body 1 of the kind of vehicle are positioned at the opposite sidepanels 3 of the body 1.

In the above-described state, when the body 1 is positioned in the sidehome position jig 200 side of the brazing section 8, the moving frame220 is moved to the opposite side panels 3 of the body 1 by the firstdriving part 225, and the dampers 250 are moved to a predeterminedposition corresponding to the body 1 of the kind of vehicle.

Next, the dampers 250 themselves are moved forward to the opposite sidepanels 3 of the body 1 by the second driving part 253 along the widthdirection of the body 1, and then the upper portions of the oppositeside panels 3 are clamped by the clampers 250.

Next, in the state in which the opposite side panels 3 of the body 1 arerestricted by the clampers 250, the roof panel 5 aligned in the roofalignment jig 101 is unloaded from the roof alignment jig 101 throughthe roof loading jig 103, and then the roof panel 5 is loaded on theopposite side panels 3 of the body 1.

Here, the roof loading jig 103 unloads and loads the roof panel 5 in thestate in which the roof loading jig 103 is mounted on the handling robot301. In the state in which the roof panel 5 is loaded on the oppositeside panels 3 of the body 1 through the roof loading jig 103, the roofloading jig 103 is separated from the handling robot 301, and then thespot welding gun is mounted on the handling robot 301.

Next, the roof panel 5 and the front/rear roof rails are spot-welded byeach of one spot by the spot welding gun of the handling robot 301 andthe spot welding gun of the welding robot 105. Next, the spot weldinggun is separated from the handling robot 301, and then the roof-pressingjig 300 is mounted on the handling robot 301.

Next, the roof-pressing jig 300 is moved to the roof panel 5 by thehandling robot 301, and then the roof panel 5 is home-positioned andpressed by the roof-pressing jig 300.

When the operation of the roof-pressing jig 300 is described in moredetail, the jig frame 310 of the roof-pressing jig 300 is moved to theroof panel 5 by the handling robot 301.

When the jig frame 310 is pressed with respect to the roof panel 5 bythe handling robot 301, the opposite side edges of the roof panel 5 aresupported by the restriction pad 320 while the skin surfaces of theopposite side edges are vacuum-adsorbed by the vacuum cups 330.

In these processes, when the restriction pin-operating rod 343 of therestriction pin cylinder 341 downwardly operates forward, therestriction pin-operating rod 343 upwardly operates backward.

Then, the restriction bracket 345 at which the restriction pin 340 isinstalled supports the bottom surface of the roof panel 5 through therestriction pin-operating rod 343, and the restriction pin 340 isupwardly inserted into the restriction hole 6 a of the roof panel 5,thereby restricting the roof panel 5.

At the same time, when the reference pin-operating rod 363 of thereference pin cylinder 361 upwardly operates backward, the referencepin-operating rod 363 downwardly operates forward.

Then, the reference pin 360 is downwardly inserted into the referencehole 6 b of the roof panel 5 by the reference pin-operating rod 363 tohold the reference position of the roof panel 5.

In the process in which the roof panel 5 is home-positioned and pressedthrough the roof-pressing jig 300, the docking bracket 317 of the jigframe 310 may be docked to the support bracket 233 of the side homeposition jig 200.

When the docking bracket 317 is docked to the support bracket 233, thefixing pin 235 of the support bracket 233 is coupled to the pin hole 319of the docking bracket 317. The pin clamper 237 on the support bracket233 is rotated depending on an operation of the pin clamping cylinder238, and clamps the fixing pin 235 together with the docking bracket 317through an operating pressure of the pin clamping cylinder 238.

Accordingly, in the exemplary embodiment of the present disclosure, theroof panel 5 loaded on the opposite side panels 3 of the body 1 may behome-positioned and pressed by the roof-pressing jig 300.

In addition, the docking bracket 317 of the roof-pressing jig 300 may bedocked to the support bracket 233 of the side home position jig 200, andthe docking bracket 317 may be stably fixed to the support bracket 233by the fixing pin 235 and the pin damper 237.

When the roof panel 5 is pressed by the roof-pressing jig 300, thebrazing assembly 400 is moved to the matching portions between theopposite side panels 3 and the roof panel 5 by the brazing robot 401.

Then, the sensor bracket 511 of the gap measurement unit 500 is movedforward to the matching portions between the opposite side panels 3 andthe roof panel 5 by the operating cylinder 520.

Accordingly, the first profile sensor 510 fixed to the sensor bracket511 is close to the matching portions between the opposite side panels 3and the roof panel 5, and the brazing robot 401 moves the first profilesensor 510 along the matching portions between the opposite side panels3 and the roof panel 5.

In this process, the first profile sensor 510 scans the matchingportions between the opposite side panels 3 and the roof panel 5 withthe laser slit to measure the gap of the matching portions. In thiscase, the first profile sensor 510 sets the virtual reference line basedon a straight-line portion of the roof panel 5, and calculates thedistance between profiles generated on the virtual reference line,thereby measuring the matching gap between the roof panel 5 and theopposite side panels 3.

The first profile sensor 510 transmits the matching gap value betweenthe roof panel 5 and the opposite side panels 3 to the controller, andthe controller applies the control signal to the second driving part 253of the side home position jig 200 depending on the measured gap valuebetween the roof panel 5 and the opposite side panels 3.

Then, the clampers 250 of the side home position jig 200 restricting theopposite side panels 3 of the body 1 are moved in the width direction ofthe body 1 by the second driving part 253, and the opposite side panels3 are flowingly moved and home-positioned in the width direction of thebody 1.

Accordingly, the matching portions between the opposite side panels 3and the roof panel 5 are laser-brazed by the brazing assembly 400, andthe gap of the matching portions may be measured by the gap measurementunit 500.

Accordingly, the matching gap between the roof panel 5 and the oppositeside panels 3 may be zero by compensating the positions of the oppositeside panels 3 by the side home position jig 200 based on the gap valuebetween the roof panel 5 and the opposite side panels 3.

As such, in the state of zeroing the matching gap between the roof panel5 and the opposite side panels 3 by compensating the positions of theopposite side panels 3, the sensor bracket 511 of the gap measurementunit 500 is moved backward by the operating cylinder 520.

Then, the brazing assembly 400 is moved along the bonding portionsbetween the opposite side panels 3 and the roof panel 5 (matchingportions) by the brazing robot 401, and the bonding portions between theopposite side panels 3 and the roof panel 5 are laser-brazed by thebrazing assembly 400.

In the state of avoiding interference with the sensor bracket 511 by theoperating cylinder 520, the brazing assembly 400 irradiates the laserbeam to the bonding portions between the opposite side panels 3 and theroof panel 5 through the laser head 430, and supplies the filler wire405 to the focus position of the laser beam through the wire feeder 450.

The brazing assembly 400 melts the filler wire 405 through the laserbeam which is the heat source, and the bonding portions between theopposite side panels 3 and the roof panel 5 may be integrally brazedthrough the melted filler wire 405.

As described above, when the bonding portions between the opposite sidepanels 3 and the roof panel 5 are brazed by the brazing assembly 400,air is supplied in the air jet passage 555 of the sensor bracket 511 bythe air blower 550.

It is possible to prevent a foreign material from being attached to thelaser-brazing portions between the opposite side panels 3 and the roofpanel 5 by injecting the air supplied by the air blower 550 in adirection perpendicular to the irradiation direction of the laser beamthrough the air jet passage 555.

When the bonding portions between the opposite side panels 3 and theroof panel 5 are brazed by the brazing assembly 400, the brazing beadsare generated at the bonding portions.

When the bonding portions between the opposite side panels 3 of the body1 and the roof panel 5 are completely laser-brazed, the side homeposition jig 200 and the roof-pressing jig 300 are positioned at thehome position.

Next, the roof-pressing jig 300 is separated from the handling robot301, and then the spot welding gun is mounted on the handling robot 301.Then, the roof panel 5 and the front/rear roof rails are spot-welded bythe spot welding gun of the handling robot 301 and the spot welding gunof the welding robot 105.

Next, after the body 1 is transferred along the transfer line 7 to thegrinding section 9, the grinding assembly 600 is moved to the brazingbead of the bonding portions between the opposite side panels 3 and roofpanel 5 by the grinding robot 601 in the grinding section 9.

Before the grinding assembly 600 is moved to the brazing bead of thebonding portions between the opposite side panels 3 and the roof panel5, the grinding wheel 630 of the grinding assembly 600 may be newlymounted on the grinding motor 620.

In this case, since the grinding assembly 600 is moved by the grindingrobot 601 along a predetermined teaching path and the brazing bead isground by the grinding wheel 630, the grinding surface of the grindingwheel 630 is positioned below the reference position thereof based onthe position of the brazing bead.

Accordingly, the stopper-operating rod 671 of the stopper cylinder 670is moved backward to release the movement restriction of the grindingmotor 620. Then, the grinding motor 620 is downwardly moved through themoving plate 650 together with the grinding wheel 630 by its own weight.

In the state, the grinding motor 620 is moved upwardly together with thegrinding wheel 630 through the moving plate 650 by applying the externalforce to the grinding wheel 630 through the separate supporter 603, andthe grinding surface of the grinding wheel 630 is positioned at thereference position.

Next, the stopper-operating rod 671 of the stopper cylinder 670 is movedforward, and the movement of the grinding motor 620 is limited by thefriction pad 675 closely contacted with the front end of thestopper-operating rod 671.

After the grinding assembly 600 is moved to the brazing bead, the visioncamera 730 of the bead inspection unit 700 mounted on the grinding robot601 together with the grinding assembly 600 senses the position of thebody 1.

The vision camera 730 vision-photographs the brazing portions of thefront glass mounting hole and the center pillar of the body 1, andoutputs the photographed vision data to the controller. The controlleranalyzes the vision data transmitted from the vision camera 730 tocalculate the position value of the body 1, and compensates the grindingposition of the grinding assembly 600 by comparing the calculatedposition value with the reference value (reference position value of thebody).

Next, the grinding wheel 630 is rotated by the grinding motor 620, thegrinding wheel 630 is moved along the brazing beads by the grindingrobot 601, and the brazing beads are ground by the grinding wheel 630.

The grinding-dust particles scattered during grinding of the brazingbeads are collected in the wheel cover 640 surrounding the grindingwheel 630, and the grinding-dust particles are sucked through the inlet645 of the wheel cover 640 and then exhausted outside the wheel cover640. In the exemplary embodiment of the present disclosure, thegrind-pressing force of the grinding wheel 630 with respect to thebrazing bead may be controlled by the pressure control cylinder 660.

In the exemplary embodiment of the present disclosure, as the brazingbeads are ground by the grinding wheel 630, the grinding wheel 630 isworn away.

In this case, since the grinding assembly 600 is moved by the grindingrobot 601 along the predetermined teaching path and the brazing bead isground by the grinding wheel 630, the grinding surface of the grindingwheel 630 is positioned above the reference position thereof based onthe position of the brazing bead.

Accordingly, the stopper-operating rod 671 of the stopper cylinder 670is moved backward to release the movement restriction of the grindingmotor 620. Then, the grinding motor 620 is downwardly moved togetherwith the grinding wheel 630 by its own weight, and the grinding surfaceof the grinding wheel 630 is positioned at the predetermined position bythe supporter 603.

Then, the stopper-operating rod 671 of the stopper cylinder 670 is movedforward, and the movement of the grinding motor 620 is limited by thefriction pad 675 closely contacted with the front end of thestopper-operating rod 671.

After the brazing bead is ground by the grinding assembly 600, thegrinding bracket 610 of the grinding assembly 600 is rotated by thegrinding robot 601.

Then, the mounting bracket 710 of the bead inspection unit 700 rotatestogether with the grinding bracket 610, and the vision camera 730 of thebead inspection unit 700 and the second profile sensor 750 arepositioned at the ground brazing bead side.

Next, the bead inspection unit 700 is moved along the ground brazingbeads by the grinding robot 601, and the ground brazing beads arephotographed by the vision camera 730 and then the photographed visiondata is output to the controller.

The controller calculates the width of the ground brazing bead byanalyzing the vision data transmitted from the vision camera 730, anddetects a defect of the ground brazing bead by comparing the calculatedwidth with a reference width (reference width of the ground brazingbead).

While performing the processes, the second profile sensor 750 detectsthe cross-section of the ground brazing bead as a 2-dimentional profileshape, and outputs the detected signal to the controller.

The controller calculates the height of the ground brazing bead byanalyzing the detected signal transmitted from the second profile sensor750, and detects the defect of the ground brazing bead by comparing thecalculated value with a reference value (reference value of the groundbrazing bead).

If a defect of the ground brazing bead is detected by the beadinspection unit 700, the detected defect is displayed on a display, andthe detected defect is transmitted to a repair process and qualityhistory management server.

As such, when the defect detection of the ground brazing bead iscompleted, the grinding robot 601 is positioned at the home position,and the body 1 to which the roof panel 5 is bonded is transferred to asubsequent process through the transfer line 7.

Therefore, the roof laser brazing system 100 according to the exemplaryembodiment of the present disclosure may laser-braze the roof panel 5 tothe opposite side panels 3 based on the body 1 depending on theprocesses described above.

Therefore, according to the exemplary embodiment of the presentdisclosure, it is possible to remove the roof molding according to theconventional art by laser-brazing the bonding portions between theopposite side panels 3 of the body 1 and the roof panel 5.

Further, according to the exemplary embodiment of the presentdisclosure, it is possible to improve an appearance of the body of thevehicle, reduce material costs, and reduce labor costs due to mountingthe roof molding, by removing the roof molding according to theconventional art.

Further, according to the exemplary embodiment of the presentdisclosure, since the roof panel 5 is home-positioned and restricted tothe opposite side panels 3 through the roof-pressing jig 300, the gapsbetween the opposite side panels 3 and the roof panel 5 are zeroedthrough the side home position jig 200 and the gap measurement unit 500,the opposite side panels 3 and the roof panel 5 are laser-brazed, andthe grinding defect of the brazing bead is automatically detected by thebead inspection unit 700, it is possible to further improve the brazingquality.

Further, according to the exemplary embodiment of the presentdisclosure, since the roof panel 5 may be laser-brazed corresponding tothe bodies 1 of various kinds of vehicles, it is possible to flexiblyproduce various kinds of vehicles, to reduce equipment-preparing time,to achieve a weight reduction and simplification of entire equipment,and to reduce initial investment and additional investment foradditional vehicles.

While this disclosure has been described in connection with what ispresently considered to be practical exemplary embodiments, it is to beunderstood that technical aspects of the present disclosure are notlimited to the exemplary embodiments suggested in the specification,but, although a person of ordinary skill in this field of art whounderstands the technical aspects of the present disclosure can suggestanother exemplary embodiment by modifications, changes, removal, andaddition of constituent elements within a range of technical aspectsthat are the same as in the present disclosure, it will also be within arange of right of the present disclosure.

What is claimed is:
 1. A roof laser brazing system which laser-brazes aroof panel to opposite side panels based on a body including theopposite side panels, comprising: a side home position jig installed ateach of opposite sides of a transferring path of the body in a brazingsection set along the transferring path of the body and that restrictsthe opposite side panels of the body; a roof-pressing jig detachablymounted on a handling robot, that is docked to the side home positionjig, and that home-positions and presses the roof panel loaded on theopposite side panels; a brazing assembly mounted on at least one brazingrobot in the side home position jig side and that brazes bondingportions between the opposite side panels and the roof panel using alaser as a heat source; a gap measurement unit mounted on the brazingassembly and that measures matching gaps between the roof panel and theopposite side panels that are pressed by the roof-pressing jig; and agrinding assembly mounted on at least one grinding robot in a grindingsection set along the transferring path of the body and that grindsbrazing beads of the bonding portions between the opposite side panelsand the roof panel, wherein the brazing assembly includes: a brazingbracket mounted on the at least one brazing robot; a laser headinstalled at the brazing bracket and that irradiates a laser beam to thebonding portions between the opposite side panels and the roof panel;and a wire feeder provided in the brazing bracket and that supplies afiller wire to a focus position of the laser beam.
 2. The roof laserbrazing system of claim 1, wherein the gap measurement unit includes aprofile sensor installed at the brazing bracket, that scans matchingportions between the opposite side panels and the roof panel, and thatmeasures gaps of the matching portions.
 3. The roof laser brazing systemof claim 2, wherein an operating cylinder is fixedly installed at thebrazing bracket, and a sensor bracket to which the profile sensor isfixed is connected to an operating rod of the operating cylinder.
 4. Theroof laser brazing system of claim 3, wherein the sensor bracketincludes an air blower jetting air and an air jet passage connected tothe air blower, and the air is jetted in a direction perpendicular to anirradiation direction of the laser beam through the air jet passage. 5.A roof laser brazing system which laser-brazes a roof panel to oppositeside panels based on a body including the opposite side panels,comprising: a side home position jig installed at each of opposite sidesof a transferring path of the body in a brazing section set along thetransferring path of the body and that restricts the opposite sidepanels of the body; a roof-pressing jig detachably mounted on a handlingrobot, that is docked to the side home position jig, and thathome-positions and presses the roof panel loaded on the opposite sidepanels; a brazing assembly mounted on at least one brazing robot in theside home position jig side and that brazes bonding portions between theopposite side panels and the roof panel using a laser as a heat source;a gap measurement unit mounted on the brazing assembly and that measuresmatching gaps between the roof panel and the opposite side panels thatare pressed by the roof-pressing jig; and a grinding assembly mounted onat least one grinding robot in a grinding section set along thetransferring path of the body and that grinds brazing beads of thebonding portions between the opposite side panels and the roof panel,wherein the grinding assembly includes: a grinding bracket mounted onthe grinding robot; a grinding motor installed at the grinding bracketto be vertically movable; a grinding wheel coupled to a drive shaft ofthe grinding motor; a moving plate connected to the drive shaft of thegrinding motor through a bushing and that is installed at the grindingbracket to be vertically movable; a wheel cover mounted on the grindingbracket to cover the grinding wheel and at which an inlet suckinggrinding-dust particles scattered by the grinding wheel is installed; apressure control cylinder fixedly installed at the grinding bracket,that is connected to the moving plate, and that controls agrind-pressing force of the grinding wheel; and a stopper cylinderfixedly installed at the grinding bracket and that selectively limitsmovement of the moving plate.
 6. The roof laser brazing system of claim5, wherein a pair of rail blocks are vertically installed at thegrinding bracket, a guide groove vertically guiding the bushing isformed in the grinding bracket, the moving plate is disposed between thegrinding bracket and the wheel cover, and a sliding block slidablycoupled to the rail block is installed at the rail block.
 7. The rooflaser brazing system of claim 5, wherein the stopper cylinder includesan operating rod that passes through the grinding bracket and operatesto move the moving plate forward or backward, and a friction pad isinstalled at the moving plate corresponding to a front end of theoperating rod.
 8. The roof laser brazing system of claim 5, furthercomprising a bead inspection unit installed at the grinding assembly,that inspects brazing beads ground by the grinding assembly, and thatsenses a position of the body, wherein the bead inspection unitincludes: a mounting bracket installed at the grinding bracket; a visioncamera installed at the mounting bracket and that vision-photographs theground brazing bead; and a profile sensor installed at the mountingbracket and that scans the ground brazing bead to measure a height ofthe brazing bead.